Multiaxial unitary alignment apparatus

ABSTRACT

The present invention provides a method and device for assessing and aligning a vehicle component and including a unitary module connecting a shaped surface associated with the nominal gage to the vehicle structure, the unitary module presenting an inner surface spaced from an outer surface having a first, second and third surface, the third surface mounted to one end of a support secured to the vehicle structure. An adjustment structure presents a first engagement surface separated from a second engagement surface associated with the outer surface, the first engagement surface and the second engagement surface being adapted to receive at least one laminar structure therebetween. The adjustment structure is generally positioned at the junction of the second or third surface sections and is adapted for translation along an axis extending outwardly from the unitary module towards the third surface, whereby said vehicle component is preferably aligned.

FIELD OF THE INVENTION

This invention relates to structural alignment. More specifically, the present invention relates to an improved alignment apparatus and method for use with vehicle components and vehicle structures which utilize shims to adjust a nominal gage in the shape of a vehicle component or vehicle structure.

BACKGROUND OF THE INVENTION

Nominal gages are generally used to determine relative spacing between or within structures. An example of a nominal gage is for use in an automotive application to measure the relative space between two structures. In addition, nominal gages may be used during the development of a vehicle for assessment and tuning of the vehicle body and closure structures. In the development of a vehicle, the interface characteristics of an object are often only realized once the entire vehicle is assembled during prototype development. In this situation, the nominal gage may be used to help measure different structural components.

However, nominal gages for engineering assessments are not generally utilized during the assembly of vehicle prototypes. Because of the cost and the nature of prototype builds, nominal gages have had limited use in the development process. In addition, with the advancement of technology, nominal gages are increasingly replaced by computer simulation. Traditionally, in the development process, a nominal gage must be specifically fabricated for the particular application and if the nominal gage is not exactly correct, a new one may need to be fabricated until the correct dimensioned nominal gage is developed.

In prior art prototype development, the manufacturing variances and a variety of dimensional variances cause variations in the alignment between various associated structures. Some of these variances can be partially attributed to weld tooling, weld process procedure, part quality, and operator error. Under these conditions, in conventional prototype building, nominal gages are utilized in non-nominal conditions and generally only provide a best fit application. Because of this, inaccurate information may be obtained during vehicle development and a significant amount of data may be lost for assessment and development. Overall, in traditional applications, the developer cannot rely upon the dimensional data for a nominal build.

Once correctly fabricated, traditional nominal gages have had limited results, based in part on the inability to correctly position the traditional nominal gage. Nominal gages fabricated and positioned in non-nominal positions limit the ability to assess and acquire information about the developing vehicle. As such, nominal gages are not generally suited for automotive fabrication and may cause an increase in the developmental process and development costs.

The above referenced shortcomings illustrate several disadvantages of traditional nominal gages which limit their application in the vehicle development process. It therefore would be beneficial to provide an improved nominal gage which improves upon the traditional nominal gage for use during the vehicle development process as further set forth below.

SUMMARY OF THE INVENTION

The present invention reduces the difficulties and disadvantages of the prior art by providing a method and device for assessing and aligning a vehicle component and including a unitary module connecting a shaped surface associated with the nominal gage to the vehicle structure, said unitary module presenting an inner surface spaced from an outer surface having a first, second and third surface sections, said third surface section rotatably mounted to one end of a support secured to the vehicle structure, a fourth surface section translationally mounted to the shaped surface, an adjustment structure presenting a first engagement surface separated from a second engagement surface associated with said outer surface, said first engagement surface and said second engagement surface being adapted for receiving at least one laminar structure therebetween, said adjustment structure positioned at the junction of at least one of said second and third surface sections and adapted for translation along at least an axis extending outwardly from said unitary module towards one of said first, second and third surface sections, whereby said vehicle component is preferably aligned.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partially exploded view of a ball and socket assembly.

FIG. 2 is a side perspective view of a multi-axial unitary alignment structure.

FIG. 3 is a front perspective of an improved nominal gage in association with the multi-axial unitary alignment structure of FIG. 2 secured to the ball and socket assembly of FIG. 1.

FIG. 4 is an elevated perspective view of a multi-axial unitary alignment structure in association with a mounting structure.

DETAILED DESCRIPTION OF THE INVENTION

As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.

In general, the present invention illustrated in FIG. 3 provides an improved nominal gage generally referred to herein by reference numeral 10, which is adapted for multiaxial movement, including translational and rotational movement, for assessing and tuning various vehicle structural members (not shown). As generally understood by those skilled in the art, during vehicle development various vehicle structural members are fabricated separately using modern fabrication techniques. As these vehicle structural members are secured to the vehicle, the alignment of the vehicle structural members varies from a computer simulation or otherwise rendered vehicle.

In assessing how these vehicle structural members relate, the nominal gage 10 may be utilized. In operation, the nominal gage 10 of the present invention includes a shaped surface 10 a fabricated in the shape of a vehicle component (not shown) which is then properly positioned along the vehicle in association with a mounting structure 22 as illustrated in FIG. 4. As illustrated in FIG. 3, the nominal gage 10 may be a regular or irregularly shaped object fabricated from a rigid material such as aluminum, steel, fiberglass or other material which remains rigid during adjustment for assessment and alignment. The shaped surface 10 a resembles the desired vehicle component and is secured to the vehicle or prototype by associating the shaped surface 10 a and a nominal gage 10, with a mounting structure 22. After the nominal gage 10 is positioned along the vehicle, its position is then measured and, if necessary, translationally and/or rotationally adjusted for alignment in a nominal body space also referred to herein as a nominal position. As designed, the improved nominal gage 10 allows engineers, operators and others to obtain better information related to the interface of the vehicle and its components, such as, but not limited to, the body, the structural members, the lighting assemblies, fascia, hood, fender and liftgate.

By way of example, not as a limitation, the embodiment of FIG. 3 illustrates the shaped surface 10 a as a head lamp structure; however, the shaped surface 10 a may take on any known structure which may be used to align relevant vehicle componentry. The nominal gage 10 is adapted for adjustable connections for movement relative to surrounding structural members and vehicle components. Since various vehicle components and structures have various shapes and sizes during development which may further vary over time, by way of example and not as a limitation, the mounting structures 22 as illustrated in FIG. 4 related to the nominal gage 10 may vary accordingly. Therefore, the nominal gage 10 can be connectably adapted to a plurality of mounting structures 22 to allow for varying spatial and dimensional relation.

The improved nominal gage 10 is adapted for use in a nominal state. However, the improved nominal gage may be used in other states, such as non-nominal states. Generally, as illustrated in FIG. 3, the improved nominal gage 10 may be used to provide a nominal state for assessing and adjusting the alignment of various structures, which in the illustrated embodiment are associated with an automobile or vehicle. The improved nominal gage 10 may be used to assess and further develop the front, rear, top and bottom portion of various vehicles such as cars, busses, trucks and trailers by securing the nominal gage 10 to a vehicle structure (not shown). In addition, the nominal gage 10 may be used to adjust the dimension of neighboring vehicle components to further help assess and align the vehicle towards the nominal position or state.

The nominal gage 10 is adapted for adjustable connection to the vehicle structure by a unitary module 30 illustrated in FIGS. 2, 3 and 4. The unitary module 30 is adapted for aligning the vehicle component in a nominal position. Generally, the unitary module includes a first engagement surface 32 presented by an inner engagement surface 32 a which is spaced from and complimenting a second engagement surface 34 associated with an outer surface 34 a. As illustrated in FIG. 3, the inner surface 32 a is cubic and the outer surface 34 a overlies the cubic shape of the inner surface 32 a, although the present invention is not considered limited by the illustrated configurations which may be alternatively configured and still considered within the scope of the present invention

Generally, the unitary module consists of a block-like structure with planar surfaces angularly orientated and adapted for connecting to the nominal gage 10, at least one of which is between 30° and 60°. The outer surface 34 a, as illustrated, further includes a first, second, third and fourth surface sections 12, 14, 16 and 18 being adjustable along multiple axes extending centrally and outwardly from the unitary module 30. The junction formed between the inner and outer surfaces 32 a, 34 a presents a receiving structure 36 adapted for receiving laminar structures, like a shim (not shown) therebetween providing desired movement.

Generally, the received laminar structures positioned between the inner and outer surfaces 32 a, 34 a provides translational movement at the first, second and third surface sections 12, 14, 16 to adjust the outer surface 34 a in relation to the inner surface 32 a. As illustrated in FIG. 2, the first, second, third and fourth surface sections 12, 14, 16, and 18 are complimentary planar surfaces which are angled relative to each. By adjusting the outer surface 34 a in relation to the inner engagement surface 32 a, the unitary module 30 allows for multi-dimensional translational movement between the vehicle component and the vehicle structure. Additional laminar structures or laminar structures with varying or cumulative dimensions may be utilized until the desired relative movement is achieved to align the nominal gage 10 with neighboring vehicle components.

A pin 40 is associated with the received laminar structures associated with the first, second and third surface sections 12,14, 16 positioned between the inner and outer surfaces 32 a, 34 a. The receiving structure 40 a is adapted for receiving a tool, for example, to assist adjustment. The receiving structure 40 allows for adjusting the nominal gage 10 while aligning neighboring vehicle components or structures towards the nominal position.

A connecting structure 50 is illustrated in FIG. 1, which is further illustrated in FIGS. 2 and 4 threadably engaged and extending outwardly and upwardly from the unitary module 30. The connecting structure 50 in FIG. 1 is adapted for releasable connection to the unitary module 30, and generally includes a threaded receiver 52 adapted for threadably receiving a threaded structure 54 and presenting a socket 54 a therebetween. The threaded receiver 52 and threaded structure 54 are adapted for receiving a rotational structure 60 within the presented socket 54 a, rotational structure 60 including a rotational body 62 and an arm 64. The arm 64 extends from the rotational structure 60, through a central aperture 56 associated with the threaded receiver 52 for connecting to the unitary module 30 to the vehicle structure. The arm 64 may include a fastening end 66 opposite the rotational body 62 for secure connection to the vehicle structure. The association of the threaded receiver 52 and socket 54 a provides a spherical engagement surface for receiving the rotational structure 60. The rotational structure 60 in association with the socket 54 a and threaded receiver 52 provides a frictional and rotational connection where rotational body 62 frictionally contacts socket 54 a while threaded receiver 52 is engaged to threaded structure 54.

As illustrated in FIG. 2, an attachment bracket 4 associated with arm 64 extends outwardly from the rotational structure 60. The attachment bracket 4 is generally adapted for releasable connection to an associated vehicle structure. The attachment bracket 4 is connectably secured to a vehicle structure, such as but not limited to the vehicle frame. Connectably securing the attachment bracket 4 to a vehicle structure provides a stationary base relative to the rotational structure 60 for rotation and/or alignment of the unitary module.

As further illustrated in FIG. 1, the rotation of the rotational body 62 associated with the socket at the connecting structure 50 allows for angular movement along plural axis which further allows the unitary module 30 to maintain a planar orientation during alignment. As the nominal gage 10 is rotated and/or translated towards the nominal position, the unitary module 30 may remain connectably secured to the vehicle structure, presenting an adaptable connection between the nominal gage 10 and the vehicle structure.

As illustrated in FIG. 3, the illustrated embodiment includes a plurality of fixtures 80 positioned along the shaped surface 10 a and providing a fixed reference coordinate for assessing the rotational position and the translational position of the nominal gage 10 before, during and after translational and rotational movement. Preferably the fixtures 80 are further spaced to provide multi-dimensional assessment in at least three axis. The fixtures 80 represent position indicators adapted to assess the state of the nominal gage 10 for alignment in the nominal position in space and in to help compare its actual position to its predicted position. A number of brackets 82 are also visible in FIG. 3, the brackets being secured to the vehicle structure near the arm 4. An alternative embodiment is shown in FIG. 4 with a bracket 82 being associated with a unitary module 30.

By way of example, the illustrated fixtures 80 are adapted for measurement, as contact probes and laser-line probes including the FARO Platinum Arm (registered trademark of FARO Technologies Inc.) to help align the nominal gage 10 into the nominal position.

As illustrated in FIG. 2, a bolt 70 associated with a washer 72 and a shaped head 74 is adapted for threadable connection to the unitary module 30. The bolt 70 extends through an aperture spatially securing the unitary module 30 relative to the translational and/or rotational alignment associated with laminar structures.

The present invention has been described in an illustrative manner. It is understood that the terminology, which has been used, is intended to be in the nature of words of description rather than of limitation. While the invention has been described with respect to specific examples including presently preferred modes of carrying out the invention, those skilled in the art will appreciate that there are numerous variations and permutations of the above described methods, compositions and techniques that fall within the spirit and scope of the invention as set forth in the appended claims. 

1. A multiaxial unitary alignment apparatus adjustably securing a vehicle component to a vehicle structure, the apparatus comprising: a unitary module presenting an inner surface spaced from an outer surface having a first, second and third surface sections, said first surface section rotatably mounted to one end of a support secured to the vehicle structure, said second surface section translationally mounted to the vehicle component; a first engagement surface presented by said inner surface and separated from a second engagement surface associated with said outer surface; said first engagement surface and said second engagement surface being adapted for receiving at least one laminar structure therebetween; and an adjustment structure secured to at least one of said first, second and third surface sections and adapted for translation along at least an axis extending through said unitary module towards one of said first, second and third surface sections, whereby said vehicle component is preferably aligned.
 2. The multiaxial unitary alignment apparatus according to claim 1 further comprising a fixed reference associated with at least one of an axis extending through said unitary module towards one of said first, second and third surface sections.
 3. The multiaxial unitary alignment apparatus according to claim 1 further comprising a rotational member extending between the vehicle structure and said first surface section.
 4. The multiaxial unitary alignment apparatus according to claim 1 further comprising a threaded structure associated with said first surface section and a threaded receiver associated with said vehicle structure said threaded structure rotatably receiving said threaded receiver for securing said vehicle structure to said apparatus.
 5. The multiaxial unitary alignment apparatus according to claim 1 further comprising a fourth surface section angularly oriented about each of said first, second and third surface sections and presenting a connecting member adapted for translational receipt of said vehicle component.
 6. The multiaxial unitary alignment apparatus according to claim 5 wherein the vehicle component further comprises a receiving member associated with a surface of said vehicle component, said receiving member adapted for engagement by said connecting member.
 7. The multiaxial unitary alignment apparatus according to claim 2 further comprising a processor in communication with a measuring apparatus and a recording device, said measuring device adapted for measuring the fixed reference point and recorded upon the recording device whereby the alignment of the vehicle structure is processed.
 8. The multiaxial unitary alignment apparatus according to claim 1 wherein said adjustment structure has receiving surface adapted for receiving a contoured surface wherein said receiving surface is complimentary the contoured surface.
 9. A multiaxial unitary alignment apparatus adjustably securing a vehicle component to a vehicle structure, the apparatus comprising: a laminar structure having a contoured surface complimentary configured in accordance with the adjustment structure. a unitary module having a first, second and third surface sections, said first surface section rotatably mounted to one end of a support secured to the vehicle structure, said second surface section translationally mounted to the vehicle component, and an adjustment structure presenting a first engagement surface separated from a second engagement surface and adapted to receive at least one laminar structure therebetween, said adjustment structure secured to at least one of said first, second and third surface sections and adapted for translation along at least one of an axis extending through said unitary module towards one of said first, second and third surface sections, whereby said vehicle component is preferably aligned.
 10. A method for vehicle alignment, the method including the steps of: associating a vehicle component with a vehicle providing at least one unitary module associated with said vehicle component, said unitary module associated with laminar structures adapted for translational movement and a rotational structure adapted for rotational movement; securing said vehicle component to said vehicle; obtaining the position of said vehicle component associated with a plurality of tooling balls and comparing said position with a fixed value; and selectively aligning said vehicle component at said adjustment structure with one of said laminar structures and rotational structure.
 11. The method for vehicle alignment according to claim 10 further including the steps of: connectably removing said vehicle component from said vehicle; and frictionally coupling a control arm by a socket associated with said rotational structure to said unitary module. 